Method of Making a Shingle and Shingle Made Thereby

ABSTRACT

A method of making a shingle and the shingle made in accordance with such method are provided, in which a shingle-forming layer of shingle material has a plurality of marks applied thereto prior to or after application of decorative granules to its tab region, and wherein the locations of the marks are sensed by a sensor, that then activates and controls the operation and placement of various shingle-completion steps as a function of the placement of the marks.

BACKGROUND OF THE INVENTION

Endeavors have been made for many years to manufacture asphalt shingleshaving appearances of natural materials, such as slate, tile, and cedarshakes.

In the course of manufacture of such shingles, it is known to use a mat,generally of fiberglass construction, impregnated with an asphalt orother bitumen material, and then to apply granules to the shingle, toadhere to the bitumen material.

When shingles are to be laid-up on a roof, with each successive courseoverlying in part, an underlying course of shingles, it is generally notconsidered necessary that the same granules be applied both to the butt(or head lap) region of the shingle as will be applied to the tab regionof the shingle, because the butt region of the shingle will be coveredby one or more next-overlying shingles, whereas the tab region of ashingle will remain visible.

Consequently, when decorative granules are to be applied to a shingle,they are generally only applied to a tab region, because that is theregion of the shingle that will be visible when the shingle is laid-upon a roof.

Various techniques have been developed for making the tab regions ofshingles decorative, often to resemble natural materials, as mentionedabove.

Often, different decorative effects are sought to be applied todifferent tabs of the same multi-tab manufactured shingle, such thateach tab can simulate an individual, tile, piece of slate, cedar shake,etc.

SUMMARY OF THE INVENTION

The present invention is directed to creating decorative manufacturedshingles, wherein various decorative effects, such as decorative granuleapplication, slot or other space in between adjacent tabs, shinglecut-off between adjacent shingles, and shingle expansion/contraction, orany of the above functions can be controlled with great precision, byfirst marking the layer of shingle-forming material, prior to, during orafter doing any of the decorative granule application, slot or spacingformation, or cut-off functions, and then sensing the mark(s) and thencontrolling with precision the placement of such subsequent functions,in an automatic manner, such that the desired shingle is manufacturedwith precision. That is, some operations to produce a shingle couldalready have occurred prior to marking the shingle-forming material tocontrol other, subsequent operations in the manufacture of the shingle.

The markings can be uniformly spaced apart, to create a predeterminedrepeatability of features in the shingles, or they can be unevenlyspaced apart to provide a predetermined appearance of non-repeatability,as desired, for example by printing or marking on a portion of themoving web or shingle-forming layer, or having a coating or tape appliedto the shingle-forming layer with a printer, such as an inkjet printeronline, or by any other means.

The markings can be provided in any of a number of manners, such as byapplying a tape to the shingle-forming layer early in its manufacture,by applying a barcode to the shingle-forming layer, directly or via atape, by applying holes (which include punctures or notches), or anyother form of marking as may be desired.

Accordingly, it is an object of this invention to provide a novel methodof manufacturing a shingle, wherein various decorative effects can beachieved with precision, by controlling the exact application of suchdecorative effects by sensing a predetermined mark on a shingle-forminglayer, prior to application of decorative effects.

It is another object to accomplish the above object, wherein one suchdecorative effect is the application of decorative granules in the tabregion of the shingle-forming layer.

It is another object of this invention to accomplish the above objectswherein the decorative effects include cutting slots or other spaces inthe tab region of the shingle-forming layer to form spaced-apart tabs.

It is a further object of this invention to accomplish the aboveobjects, wherein one such decorative effect is the cutting of theshingle-forming layer into separate shingles of predetermined length.

It is yet another object of this invention to accomplish the aboveobjects, wherein one such decorative effect is controlling the expansionand/or contraction of the shingle-forming layer prior to cutting theshingle-forming layer into separate shingles, by controlling thehumidity in the shingle manufacturing environment. Such is desirable fordimensional stability of a paper or polymer based or tape appliquébearing a marking scheme prior to application to the shingle-forminglayer.

Other objects and advantages of the present invention will be readilyapparent to those skilled in the art upon a reading of the followingbrief descriptions of the drawing figures, the detailed descriptions ofthe preferred embodiments, and the appended claims.

BRIEF DESCRIPTIONS OF THE DRAWING FIGURES

FIG. 1 is a top perspective view of a schematic illustration of themanufacture of shingles by the application, of various decorativeeffects to a shingle-forming layer as it is being conveyed along alongitudinal path, and wherein marks are applied to the shingle-forminglayer prior to application, of decorative effects thereto, such marksbeing applied to the shingle-forming layer in the form of a tape that isapplied thereto.

FIG. 1A is a diagrammatic illustration of the placement of a sensor ontothe shingle-forming layer after application of the marking feature, withthe mark position being responsive to something that has alreadyoccurred, for triggering or controlling subsequent events.

FIG. 2 is a top perspective view, fragmentally illustrating a portion ofa shingle-forming layer having sensible marks applied thereto in theform of holes or punctures.

FIG. 3 is an illustration similar to that of FIG. 2, but whereinbarcode(s) are applied to the shingle-forming layer, to comprise themarks.

FIG. 4 is an illustration similar to that of FIGS. 2 and 3, but whereina tape having marks thereon similar to those of FIG. 1 is applied to theshingle-forming layer, and wherein the shingle that is made is amulti-layer shingle.

FIG. 5 is an illustration similar to that of FIGS. 2 and 3, but whereinthe marks are applied in the form of a tape, and which are seeminglyrandomly disposed on the tape, to yield an appearance ofnon-repeatability of features in the completed shingle.

FIG. 6 is a top plan view of a shingle in accordance with thisinvention, wherein the marks appear on a tape that is applied to theshingle, and are synchronized above the placement of slots betweenadjacent tabs of the shingle.

FIG. 7 is an illustration similar to that of FIG. 6, but wherein themarks and tab-separating slots are seemingly randomly located along thelength of the shingle.

FIG. 8 is a top view of a shingle made in accordance with thisinvention, wherein four distinct decorative effects are shown in the tabregions of the shingle, with the tab regions being spaced apart byslots.

FIG. 9 is an illustration similar to that of FIG. 8, but wherein shadelines are illustrated adjacent the left edge of each tab of the shingle.

FIGS. 10, 11 and 12 are top plan views of different shingles made inaccordance with this invention, wherein different aesthetic effects arerealized.

FIGS. 13, 13A and 13B represent a multi-layer shingle (FIG. 13) whereina full backing or posterior layer is shown in FIG. 13A, and wherein apartial backing or posterior layer is shown in FIG. 13B

DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail reference is first made to FIG.1, wherein a shingle-forming layer 10 is generally illustrated as beingconveyed from left to right, in the longitudinal direction of the arrow11. It will be understood that the shingle-forming layer is beingconveyed on a conveyor, generally of the roller type (not shown), andthat the layer 10 is fragmentally illustrated. The layer 10 is comprisedof a base mat of reinforcement material, preferably fiberglass, althoughthe same can be an organic material, and wherein the reinforcementmaterial is already impregnated with an asphalt or other bitumenmaterial.

The bitumen material also appears on the surface 12, to receive granulesdispensed therefrom from a granule applicator 13. The granule applicator13 has granules 14 therein which will normally dispense lower gradegranules, that can be reclaimed granules (also called headlap granules)therefrom, into a butt or headlap region 15 of the shingle-forminglayer, which region 15 is above a tab region 16 of the shingle-forminglayer, as shown in FIG. 1.

Generally, the granules 14 dispensed from the granule dispenser orapplicator 13 are dark in color, although they can, if desired, be ofany other shade.

Because the grannies dispensed from the applicator 13 are principallydispensed into the butt or headlap region 15, the applicator 13 need notbe of the full width 17 of the shingle-forming layer, although, ifdesired, the applicator 13 can be of full width as shown by the phantomextension portion 18 thereof, if it is desired to initially, or at anyother time, dispense headlap granules also into the tab region of theshingle-forming layer 12.

It will be understood that, in the manufacture of a shingle-forminglayer 12 in accordance with this invention, the shingle-forming layermay be manufactured in the form of a pair of side-by-sideshingle-forming layer portions 12 and 20, with the portion 20 beingfragmentally shown in phantom in FIG. 1, such that the layer portions 12and 20 are simultaneously formed, in accordance with that portion of thedisclosure of parallel, shingle-forming layers as manufactured accordingto U.S. Pat. No. 6,212,843, the complete disclosure of which is hereinincorporated by reference.

For the purposes of simplifying the presentation of the invention inaccordance with this application, hereafter, only a singleshingle-forming layer 12 will be discussed.

It will also be understood that it is not essential that headlapgranules 14 be applied at all, in accordance with this invention, priorto the application of decorative granules as will hereinafter bediscussed, and prior to the application of slots and shingle cut-off,although the application of headlap granules 34 in the headlap or buttregion 15 of the shingle is preferred.

Marks are applied to the shingle-forming layer 12, preferably in thebutt region 15, and such marks may be applied by applying a tape 21,supplied from a roll 22 or the like, which tape becomes attached to apreferably upper surface of the shingle-forming layer 12 by means of anadhesive 23 applied from an adhesive applicator 24 of a roller or liketype, as shown in FIG. 1, such that the lower surface of the tapeadhesively sticks to the upper surface of the tab portion 15 of theshingle-layer 12, and preferably onto headlap granules that are appliedin the butt region 15 of the shingle-forming layer 12.

A roller 25 or the like can urge the tape 21 into contact with the uppersurface of the butt region 15 of the shingle-forming layer 12, as shown.

The tape 21 has a plurality of marks 26 thereon, which, in theembodiment shown in FIG. 1, can be darkened areas of the tape 21, whichcan be evenly spaced apart as shown to provide a predeterminedrepeatability of features of other shingle-completion steps that willsubsequently be discussed, or which darkened areas 26 may, if desired,be unevenly spaced apart from each other to provide a predeterminednon-repeatability of features of shingle-completion steps that willsubsequently be discussed.

A sensor 30 is provided, for sensing the presence of marks 26 passingtherebeneath and communicating, in response thereto, via a signal line31, to a computer or other controller 32, preferably of themicroprocessor type. In the case of a wireless transmission of thesignal from the sensor 30 to the controller 32, a physical signal line31 would not be necessary.

It will be understand that the sensor 30 may take on various forms, suchas a lightness or darkness detector, a metal or magnetic detectiondevice, a barcode reader, an infrared detection device, a hole detectiondevice, a photocell, a CCD array image reader or any other form ofdetection device, many types of which are well known in the art, whichcan detect some difference caused by a mark of various types such asthat 26, passing therebeneath.

Once the sensor 30 detects the presence of a mark 26 passingtherebeneath, it can then control the application of various othershingle-completion features, which control is exercised subsequently tothe sensing of marks 26 by the sensor 30.

One such feature that can be controlled is the humidity environment inwhich the shingle-forming layer 12 continues to pass in the direction ofthe arrow 11. To this end, the controller 32 is operatively connected toa humidifier 33, supplied with water via a line 34, in the manufacturingenvironment 35 in which the shingles are being made, such that moisture36, provided from the humidifier 33 is added to the environment 35 inamounts as determined by the controller 32. By proper control of thehumidity in the environment 35, any expansion and/or contraction of thelayer 12 as shingles are being formed therefrom can be control led withprecision. Humidity control facilitates dimensional stability of themarking tape 21, as well.

In FIG. 1 there are also shown a pair of decorative granule applicatorsystems 37 and 38. While only two such systems 37 and 38 are shown, itwill be apparent that any desired number of such systems may be used, inaccordance with the present invention.

The applicator system 37 includes a decorative granule applicator 40fragmentally illustrated, having granules 41 therein, with an openablebottom 42 controlled in some manner within the skill of those in thisart, but shown closed in the direction of arrows 39. In the particularembodiment shown, the openable bottom 42 is shown as being controlled bya pair of gears 43 controlled by a gear box 44, that, in turn, iselectrically controlled via control line 45 from the controller 32. Itwill be apparent that other forms of granule application may be utilizedother than that shown for the system 37, and that the discharge fromopenable bottom 42 may be replaced by any other means of discharge.Similarly, the gearing and gear box 43, 44, respectively represents onlyone representative means of controlling the application of granules fromthe applicator system 37.

Thus, the dropping of decorative granules 41 is controlled from thecontroller 32, that in turn responds to the sensor 30 detecting markssuch as those 26.

The decorative granule applicator 37 is also controlled as to itslongitudinal position leftward or rightward, in order to control theprecise placement of dropping of granules therefrom onto the uppersurface of the shingle-forming layer 12. Thus, variations leftward andrightward in the positioning of the applicator 40 can take place in thatthe applicator 40 is connected via positioning rod 46 to a means formoving the applicator 40 leftward and rightward. One such means can bethe use of a worm gear 47, rotatable as determined by a motor 48 thatcontrols the rotation of the worm screw, and by which a bearing 50 thatrides along the worm gear 47 is moved leftward and rightward uponrotation of the motor 48, and with the rotation of the motor 48 beingcontrolled via control line 51 from the controller 32, which, again, is,in turn, responsive to the detection of marks 26 by the sensor 30.

The decorative granule system 38, likewise is adapted for droppingdecorative granules on the upper surface of the shingle-forming layer12, by opening openable bottom 52 in the direction of the arrows 53.

In a similar manner to the system 37, the system 38 is operated via apositioning rod 53, a bearing 54, a worm gear 55, motor 56, control line57, and the controller 32 upon sensing of marks 26 by the sensor 30.

It will thus be seen that the granule applicator systems 37 and 38 areshown to have accurately deposited granules of different decorativeappearances that start and stop as viewed longitudinally, withprecision, as shown by the dimensions A and B for the tab-forming zones58 and 60, respectively.

The manner in which the sensor 30, by sensing marks 26 and operating tocontrol the cutting of slots or other spaces in the tab region 16 of theshingle-forming layer 12, to form spaced-apart tabs will now bediscussed. The slot or other space-forming system 62 comprises a slot orspace cutter 63, positionable into and out of contact with theshingle-forming layer 12, and positionable longitudinally for preciseplacement of the slot or other space that is to be cut. In theembodiment shown, the cutter 63 is adapted to be moved upwardly ordownwardly in the direction of the double-headed arrow 64, to form theslot 65 or other space between tab zones 58 and 66 in FIG. 1. Onemechanism for moving the cutter 63 to form the slot 65 or other space,is in the form of a cam 67, driven via a drive mechanism 68, controlledvia control line 79 from controller 32 and with the cam 67 operatingagainst a cam follower 70 that drives a rod 71 carried thereby upwardlyor downwardly, as shown in FIG. 1 to cut a slot 65 or other spacebetween adjacent tabs.

The entire system 62 can also be moved leftwardly or rightwardly asshown in FIG. 1 in that it is mounted to an “L”-shaped bar 72 that, inturn is carried by a bearing 73 that is mounted on a worm gear 74, suchthat upon rotation of the worm gear 74, the bearing 73 moves the system62 leftward or rightward, and with the worm gear 74 being controlled bythe motor 75 that is connected via control line 76 to the controller 32,such that upon detection of marks 26 by the sensor 30, the system 62 canbe placed leftward or rightward, in the precise position desired and canbe activated to engage the shingle-forming layer and cut a slot 65 orother space between tab zones to form tabs such as that 65 of FIG. 1.

A system 80 will now be discussed for cutting the shingle-forming layer12 into discrete shingles. The system 80 as shown in FIG. 1, includes ashingle cutter 81 adapted for movement upwardly or downwardly as shownby the double-headed arrow 82. Such vertical movement can be controlledby a plurality of cams 83 engaged with cam followers 84 that in turnoperate drive rods 85 that move the cutter 81 upwardly or downwardly asdriven by the cam drive mechanism 86. The drive mechanism 86 is, inturn, controlled for movement of the cutoff system 80 leftwardly orrightwardly in a manner similar to that provided for the system 62, inthat an “L”-shaped bar 87 between the cam drive 86 and a bearing 88mounted on a worm gear 90 is controlled in its leftward and rightwardmovement by a motor 91 that is connected via line 92 to the controller32. Thus, upon the sensor 32 sensing marks 26, the longitudinalpositioning of the cutter mechanism 80 can be precisely set, and theactivation of the cam drive 86 to move the cutter 81 downwardly iscontrolled from the controller 32 via line 93, again, upon sensing bythe sensor 30 of marks 26.

It should be apparent from the above, that only representativemechanisms are discussed for controlling the opening and closing of thedecorative granule applicator systems 37 and 38, for controlling theleftward and rightward positioning of the decorative granule applicatorsystems 37 and 38, for controlling the manner in which the slot or otherspace cutting system 62 makes cutting contact with the shingle-forminglayer 12, for controlling the leftward and rightward positioning of theslot or other space-cutting system 62, for controlling the manner inwhich the cutter 81 makes contact with the shingle-forming layer forcutting the same into discrete shingles, for controlling the manner inwhich the shingle cutting system 80 moves leftward or rightward, forproper cut-off placement as determined by the controller 32 and forcontrolling humidity in the manufacturing environment. As isspecifically shown in FIG. 1, representative mechanisms and controllingapparatus are shown. However, it will be understood that in place of theparticular systems shown, other systems either electrical and/ormechanical can be utilized. For example, other positioners than wormgears can be used, such as electrically operated solenoids, mechanicallyor pneumatically operated piston cylinders, or the like. Also, in lieuof the cams and cam followers described above, solenoids, pistons or thelike could be used in their places. Also, for purposes of cutting theslots or other spaces between adjacent tabs, and or for use in cuttingthe shingle-forming layer into discrete shingles, apparatus such as thatshown in U.S. Pat. No. 6,212,843 may be used, for cutting slots betweentabs, for use as a shingle cut-off, and even for use in severing a pairof shingle-forming layer portions 12 and 20 (as is fragmentarily shownin phantom) in FIG. 1, along a common severance line. Thus, theapparatus as shown in FIG. 1 is merely one representative apparatus foraccomplishing the shingle-completion steps in accordance with thisinvention. For purposes of transmission of signals, for example, forcontrol of various mechanisms and apparatuses in the operation, wirelesstransmitted signals may provide an alternative to hardwired signallines. Such signals may be electrical, electronic, optical, electrooptic in nature, or of any other form.

There are several advantages to overall shingle design and aestheticswith regard to synchronization of color blend drops to tabs or fixedpositions on a shingle and synchronization of shingle length. Whencutouts are evenly spaced on a shingle and there is a fixed length it iscritical that the synchronized length occur at the correct positioningsuch as in the middle of a cutout slot to give a balanced or center cut.This is important when applying multiple shingles so that a desiredappearance of a uniform and seamless joint is present. Synchronizationto the cutout slot position therefore is a critical advantage to aproduct having two or more layers. The advantage applies to a top layerwith side edge cutouts and a bottom layer with a straight cut where thetop layer is applied over the bottom layer and then cut to length andposition by a synchronization.

Other applications to shingle product design and aesthetics couldinvolve:

-   -   (a) petticoat (posterior layer extending below anterior layer)        or top to bottom offset between adhered multiple layers        including uniform and non-uniform bottom edge cut designs and        varying heights of petticoat top to bottom offset and on-off        petticoat height variations where a portion of the bottom edge        is offset and another adjacent or non-adjacent portion is not        offset form the bottom edge of two or more multiple layers:    -   (b) cutouts could be in non-uniform locations on the top or        other layer locations and could be on one or more side edge        locations;    -   (c) shingle lengths could also be of pre-designed lengths that        are intended to be variable for a particular aesthetic        appearance such as to simulate a wood shake appearance;    -   (d) cutout widths could vary in width across an individual        shingle surface;    -   (e) cutout widths are thought to have the best aesthetics with        uniform cutout widths less than one inch in width:    -   (f) cutouts could also vary in non-uniform height and could also        vary in height when combined with varying widths;    -   (g) cutouts can also vary in non-uniformity of top to bottom        dimension, such as not to be a continuous straight line on one        or more sides. The same could hold true for left to right        dimensions such as at the top or bottom of a cutout; and/or    -   (h) a slit or slice could also be considered as a cutout.

With reference to FIG. 1A, it will be seen that the shingle-forminglayer 12′ may have granules applied via granule drop 37′ after bitumenis applied from lank 9′ while the layer 12′ passes between rollers 7′and 8′, and that after the granules are applied at 37′, theshingle-forming layer passes around roller 38′, and then the sensor 30′senses a mark that has been applied to the shingle-forming layer 12′after the marking tape 21′ is applied subsequent to the granuleapplication at 37′. The mark applied by the marking tape 21′ or via someother marking means is thus responsive to something that has alreadyoccurred and serves to trigger and/or control subsequent events.

With reference now to FIG. 2, it will be seen that a shingle 100 isfragmentally shown, as having a plurality of holes 101 applied ingroupings 102, as shown, by means of a mechanism 103 movable upwardlyand downwardly in the direction of the double-headed arrow 104, asshown, by a suitable motor, solenoid or the like (not shown), which inturn carries a base 105 (shown in phantom), which base, in turn, carriesa plurality of piercing members 106, for piercing the shingle-forminglayer 107 to make a plurality of holes 101 that in a given collection102 provide a mark, adapted for being sensed by a sensor 30 or the like,as described above, for accomplishing the shingle-completion stepsdescribed above. It will understood that the holes 101 may be of anydesired size or shape, may pass entirely through the shingle-forminglayer 107, or not, may take the form of notches or any other shapes,etc.

With reference now to FIG. 3, it will be seen that a shingle-forminglayer 200 is shown, in which barcode(s) 201, identical or different fromeach, other, as may be desired, are applied to the upper surface 202 ofthe shingle-forming layer 200, by means of a barcode printer or the like203 applying the same onto a tape 204 applied to the upper surface ofthe shingle-forming layer 200. Alternatively, the barcode(s) may beapplied directly to the upper surface of the shingle-forming layer, asmay be desired. In a similar manner as described above, the barcode(s)may be read by a sensor such as that 30 or the like, for controlling theshingle-completion steps. Such barcodes can be at least one-dimensionalin nature, or two-dimensional or more complex images, depending upon thecomplexity of the information necessary to control multiple actions andoperations in the manufacture of the finished shingles.

With reference to FIG. 4 a shingle-forming layer 300 is shown,comprising a multi-layer formation, including an upper layer 301 and alower layer 302, adhesively secured together to form a multi-layershingle, after the shingle-forming layer 300 is severed into discreteshingles.

As with the embodiment shown in FIG. 1, the upper surface of theshingle-forming layer 300 is provided with a tape 303 having a pluralityof marks 304 thereon for detection by a sensor such as that 30 or itsfunctional equivalent, as described above, for controllingshingle-completion steps.

With reference now to FIG. 5, as distinguished from the evenspacing-apart of the marks 304 as shown for the embodiment of FIG. 4,the marks 404 on the shingle-forming layer 400 of the embodiment of FIG.5, are unevenly spaced apart to provide a predeterminednon-repeatability of features of subsequent shingle-completion steps.

In FIG. 6 a shingle 500 is shown, having a tape 501 on the uppersurface, which tape 501 has a plurality of marks 502 thereon, with themarks 502 being spaced apart to define placement precisely alignedtherewith for slots 503. The tape 501 is applied in a manner similar tothat described above for the tape discussed with respect to FIG. 1, andthe slots 503 are likewise controlled in their placement by a controllersuch as that 32 of FIG. 1 that, in turn, is actuated by means of asensor such as that 30 of FIG. 1 sensing the marks 502.

In FIG. 7 a shingle 600 is presented, having a tape 601 applied to anupper surface thereof, with irregularly spaced marks 602, that dictatevia a sensor such as that 30 and controller such as that 32, theplacement of slots 603 between adjacent tabs 604 of the shingle 600, tocorrespond to the placement of marks 602, in the longitudinal direction.

With reference now to FIG. 8, a shingle 700 is shown, having four tabs,each with its own decorative covering of granules thereon, each havingits own aesthetic appearance.

The four different granule drops that produce the differently decoratedtabs 701. 702, 703 and 704 are controlled in the manner described abovewith respect to FIG. 1. As was discussed above with respect to FIG. 1,any desired number of granule drop systems such as those 37 and 38 canbe used. In the case of the shingle of FIG. 8, preferably four suchsystems are used to produce the different aesthetic presentations shownfor the tab portions 701-704 of the shingle 700. Likewise, the preciseplacement of slots such as those 705 between adjacent tabs may becontrolled in the manner described above with respect to FIG. 1. It willbe understood that the shingle 700 of FIG. 8 could be an anterior layerof a multilayer shingle, where a posterior layer (not shown) may haveportions visible between and/or extending below the lower edges of thetab portions 701-704.

It will be understood that where different decorative granuleapplications are applied to shingle tab areas, such as those shown inFIG. 8, those shown in FIG. 1, or those shown in the other figures ofthis application, any individual granule drop from, its granuleapplicator may be comprised entirely of granules of a given color orsize, or may be comprised of predetermined blends of granules ofdifferent colors and/or sizes, but that the different presentations forthe different tabs, such as shown in FIG. 5 depict different visualappearances for the tabs.

With reference to FIG. 9, a shingle 800 is illustrated having tabs 801,802, 803 and 804, of different visual decorations, as described abovewith respect to FIG. 8, but in the case of the tabs of FIG. 9, shadingareas 805 are shown on the left side of each tab, representing anothervisual decoration that may be applied by sensing marks and controllingthe application of granules, for example, of darker selection, from agranule applicator, all as sensed and controlled in a manner such as isset forth above with respect to the description of FIG. 1.

With reference to FIG. 10, a multi-layer shingle 900 is shown, having anupper layer 901 and a lower layer 902. The upper layer has tabs 903precisely spaced apart in a manner as controlled by a system such asthat described above with respect to FIG. 1. However, in theillustration of FIG. 10, a shim provides the layer 902, either of fullheight or approximately half height, laminated behind the layer 901, andwherein decorative frontal or anterior surface portions 904 for theposterior layer 902 are visible between adjacent tabs 903 to provide adragon's tooth effect. In the embodiment shown in FIG. 10, the visibleportions 904 of the anterior surface of the posterior layer 902 are ofthe same decorative or aesthetic effect, but it will be understood thatsuch could be of different aesthetic effects. It will also be apparentthat the control of placement of the decorative granules on theposterior layer 902 can be as controlled in the manner described abovewith respect to the various mechanisms of FIG. 1.

With reference now to FIG. 11, a shingle 920 is illustrated as having anupper or anterior shingle layer 921 and a lower or posterior shinglelayer 922 adhesively secured thereto to make a laminated two-pieceshingle. The shingle 920 is also of the dragon's tooth type, whereinspaced apart tabs 923 have angled right and left edges and have spacestherebetween as determined by the slot or space making technique asdescribed above with respect to FIG. 1 are made, and with the spacesbetween the tabs 923 showing anterior surface portions of posteriorlayer 922 therethrough, as shim zones 924. It will be noted that each ofthe shim zones 924 and each of the tabs 923 have different decorativeconfigurations, either by having different colored and/or sized granulesthereon, or by having different mixes of various colored granules and/orgranule sizes thereon, but wherein each tab and each shim zone presentsa different aesthetic variation. It will be understood that the variousdecorative tab areas and shim areas as shown in FIG. 11 may have theirplacements precisely controlled in accordance with the method describedabove with respect to FIG. 1.

With respect to FIG. 12, a shingle 940 is illustrated, of the singlelayer type, in which the spaces 941 between adjacent tabs 942 are morewidely spaced apart than the slots, for example for the shinglesillustrated in any of FIGS. 6-9, to yield a dragon's tooth effect, andwherein the anterior surfaces of the tabs 942 each have some decorativevariation from the other tabs, which variations can be in differentcolors or sizes of granules, different blends of colors or sizes ofgranules, or the like, all as may be desired.

In FIG. 13, the anterior layer 950 and posterior layer 951 for theshingle 952 are shown, with the posterior layer portions 953 and 954providing a petticoat effect 953 beneath anterior tabs 954 and visibleposterior portions 955 between anterior tabs 954, respectively. FIG. 13Ashows a full height backing or posterior layer 951 behind anterior layer952 and FIG. 13B shows a partial height backing or posterior layer 956behind anterior layer 952, each with a petticoat portion 953 and visibleportions 955 as discussed above. The tabs 954 could be different incolor or shading, in whole or in part, as may be desired.

It will be understood from the above that many variations can be made inthe shingles that are made in accordance with the process of thisinvention, and that variations can be made in the processes as well. Forexample, the marks that are made on a tape may be in the shape of asquare or rectangle, and that the tape may be a film or other thinsubstrate attached or adhered to the shingle-forming layer. The markscan be printed on either or both sides, for example of a clearsubstrate, and the substrate may be comprised of paper, parchment, orfilms commonly used in the roofing industry and applied to roofingshingles or rolls. Such tapes can be, but are not limited to, those ofpolyester, nylon, polypropylene or the like, and may be metalized orcomprise combinations of layered film types to add integrity or heatresistance. To add resistance where tension, can be a concern, areinforced film substrate with reinforcement strands in thelongitudinal, or machine direction may, if desired, be included ascomponents of the tape.

The marks can be magnetic in nature, if desired, can have colorcontrast, can be radioactive, or can be otherwise measurable ordistinctive, to be detected by a sensor having a means for detection ofsuch marks.

The shingle-forming layer can be, if desired, of a contrasting colorrelative to the marks, such as dark in the case of a light mark, orlight in the case of a dark mark, or can be metalized or clear innature, such that dark asphalt showing through a clear tape can givecontrast to a lighter colored mark. It will also be clear that themarks, whether applied by means of a tape or the like, or not, can beapplied to either the top or bottom side of a shingle-forming layer, asmay be desired, and that the marks can be of various shapes, widths andlengths as may be required by a desired sensor, if the mark is appliedto a tape or the like, such tape could also function as a release film,in that release films are commonly used in the roofing industry to beapplied against an adhesive strip, in bundling of shingles, to keepadjacent bundled shingles from sticking together, but which willfacilitate their separation when installed on a roof. The tape couldalso be light colored in nature when applied over a darkershingle-forming layer, and in instances in which the mark is in the formof perforations in such a tape, the darker color showing through thetape could be the mark that is detectable by a sensor. It will also beapparent that in accordance with this invention, shingles having no tabsmay be enhanced by having in their tab regions which comprise the lowerportion of the shingle as it is installed on a roof, differentdecorative presentations adjacent each other, precisely applied inaccordance with the features of the present invention, yet wherein noslots or spaces are formed in the tab regions and consequently nodistinct tabs as such are presented.

It will thus be apparent from the foregoing that various modificationsmay be made in the details of shingle construction, as well as in themethod of making such shingles, all within the spirit and scope of theinvention as defined in the appended claims.

1. (canceled)
 2. (canceled)
 3. (canceled)
 4. (canceled)
 5. (canceled) 6.(canceled)
 7. (canceled)
 8. (canceled)
 9. (canceled)
 10. (canceled) 11.(canceled)
 12. (canceled)
 13. (canceled)
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 15. (canceled)16. (canceled)
 17. (canceled)
 18. (canceled)
 19. (canceled) 20.(canceled)
 21. A manufactured shingle in which the shingle has a buttregion and a tab region with the tab region having decorative granulesapplied thereto, the shingle comprising: (a) a shingle-forming layercomprised of shingle reinforcement material impregnated with a bitumenmaterial, the layer having a butt region and a tab region; (b) anoptional layer of headlap granules on an upper surface of at least thebutt region of the shingle-forming layer; (c) a plurality of markscarried by the shingle-forming layer, with the marks being provided atpre-determined longitudinally spaced-apart distances from each other andcomprising sensing means for aiding in controlling the timing andplacement of features of the shingle; (d) said marks comprising any of:(i) a marking tape with a plurality of marks thereon; (ii) a pluralityof groups of holes; (iii) barcode(s); (iv) placement indicated forplacement of decorative granules; (v) placement indicators for placementof different colored granules; and (vi) placement indicators forplacement of different sized granules.
 22. A manufactured buildingproduct in which the building product has a butt region and a tab regionwith the tab region having decorative granules applied thereto, theshingle comprising: (a) a building product-forming layer comprised ofbuilding product reinforcement material impregnated with a bitumenmaterial, the layer having a butt region and a tab region; (b) anoptional layer of headlap granules on an upper surface of at least thebutt region of the building product-forming layer; (c) a plurality ofmarks carried by the building product-forming layer, with the marksbeing provided at pre-determined longitudinally spaced-apart distancesfrom each other and comprising sensing means for aiding in controllingthe timing and placement of features of the building product; (d) saidmarks comprising any of: (i) a marking tape with a plurality of marksthereon; (ii) a plurality of groups of holes; (iii) barcode(s); (iv)placement indicated for placement of decorative granules; (v) placementindicators for placement of different colored granules; and (vi)placement indicators for placement of different sized granules. 23.(canceled)
 24. (canceled)
 25. A shingle according to claim 21, whereinthe marks comprise high visual contrast areas relative to theshingle-forming layer to which they are applied.
 26. (canceled)
 27. Ashingle according to claim 21, wherein the marks comprise coded holesapplied to the shingle-forming layer.
 28. (canceled)
 29. (canceled) 30.(canceled)